Cooler

ABSTRACT

A cooler system having improved insulative properties. The cooler system includes, in various preferred embodiments, thicker sidewalls having insulative materials with improved thermal qualities, one or more reflective surfaces, a sealing mechanism to minimize the leakage of cold air, an insulative apron for containing cold air around the contents of the cooler, compression mechanisms for compressing the upper lid against the side walls of the cooler and many other features to improve the thermal benefit of the cooler.

FIELD OF THE INVENTION

[0001] The present invention relates to the field of portable insulatedcooler systems.

BACKGROUND OF THE INVENTION

[0002] Portable coolers are widely used to store and transport items ina chilled environment. These coolers are typically of a “chest” designwith thermally insulated plastic or Styrofoam walls, tops and bottoms.Such coolers are generally effective for only a relatively short periodof time, particularly when exposed to direct sunlight. Coolers of thistype are used not only for transport and storage of food items forrecreational purposes but also for such uses ranging from food vendors,construction industry to medical transport of organs, blood, medicineand other critical items. All of these uses and other uses would greatlybenefit from an insulated cooler system having greatly increased thermalbenefit.

[0003] Typical portable coolers presently are of a chest design with ahinged upper lid or small soft sided bags. The insulation material isnormally polyurethane or polystyrene material, up to two inches thick onthe walls and one seven/eighths on the upper lid. Basically, the coolerspresently available are typically boxes having one to two inches ofinsulation material. These coolers tend to have a removable tray,handles and a drain port. The industry standard color for at least thelids is white. These coolers tend to be effective for only short periodsof time depending on the amount of time in direct sunlight and theoutside ambient temperature and the amount of coolant and or ice.

[0004] The soft bag coolers are typically flexible PVC lined bags with asmall amount of foam insulation. Also available are drink holders thathave a small amount of neoprene or foam insulation into which a drinkcan be inserted.

[0005] There are more complex cooling systems, but these tend to beexpensive and difficult to transport and maintain.

[0006] There presently is a need for a cooler that has improved thermalbenefit to enable stored items to maintain their temperature and stillbe affordable.

SUMMARY OF THE INVENTION

[0007] The present invention provides an affordable cooler system thatgreatly increases the thermal benefit over existing coolers. The coolerof a preferred embodiment of the present invention can be produced in avariety of sizes and shapes for use not only for recreational users butfor such diverse markets as medical transport, military, floral, fishingindustry, military, catering, recreational vehicles, boating, fooddelivery, tail-gating, golfing, special events, sporting events and manyother uses.

[0008] The preferred embodiment of the present invention includes acooler having increased insulative properties by using thicker sidewallswith insulation material having greater thermal insulation ratings. In apreferred embodiment, the cooler includes side walls having a three inchcavity filled with expanded foam polyurethane have a rating of R7 orgreater per inch.

[0009] Another feature provided in some preferred embodiments of thepresent invention is the use of highly reflective vinyl surfaces. In onepreferred embodiment, the cooler uses vinyl surfaces having a reflectiverating of 85% UV or greater. The vinyl surfaces may be applied onto thesurfaces by adhesives.

[0010] Some preferred embodiments use unique “tooth” designs on theupper surfaces of the side walls with a mating “tooth” on the lowersurface of the upper lid. This “tooth” design minimizes the leakage ofcold air from the interior of the cooler. In one preferred embodiment,the tooth design provides four continuous points of contact around theperiphery of the cooler. Other embodiments provide differing number andtypes of continuous points of contact.

[0011] Compression mechanisms are also provided in some preferredembodiments to compress the upper lid against the upper surfaces of theside walls to further minimize the leakage of cold air from the interiorof the cooler. These compression mechanisms can include the use ofcompression straps, along with cam operated buckles. Another type ofcompression mechanism that can be used either alone or in combinationwith the tooth design and/or the compression straps include the use ofbuckles, snaps or other types of fasteners that pull the upper lid intoengagement with the upper surfaces of the side walls.

[0012] Another feature of a preferred embodiment of the presentinvention includes an insulative apron formed of an insulated foammaterial with or without a reflective surface and waterproof lining. Theinsulative apron may include rounded or split corners to enable it to betucked around the contents of a cooler to trap the cold air around thosecontents. Other features that the apron may include are beveled edges,pockets for certain items, a thermometer, and a fastener, such as hookand loop fasteners, to enable it to be secured to the upper lid when notin use in order to add insulation to the upper lid.

[0013] Dry ice pockets may be included in preferred embodiments of thepresent invention for the convenient use of dry ice. These dry icepockets include an overlapping wrap bound by an elastic band to maintaincompression of the wrap around the dry ice as it evaporates.

[0014] The cooler of a preferred embodiment may also use pour bottleshaving a layer of insulation foam. Water or other liquids may bepre-frozen in the pour bottles that are then used to chill the coolerand for dispensing the liquid as needed.

[0015] Battery powered lights may also be mounted within the cooler toenable their use in dark environments. Also, clips or hook and loopfasteners similar those used with the apron may be incorporated toenable flashlights to be clipped into the cooler.

[0016] The cooler of a preferred embodiment may also include externallyaccessible compartments and inserts such as a cutting board to improvethe convenience of the cooler. The cooler may also include horizontaland vertical grooves for shelves and/or cooler compartmentalization.

[0017] Other features that may be included in a cooler of the presentinvention includes a large port drain with a screw cap, a lower surfaceof the internal shell canted towards the drain port to enable drainagewithout the necessity of tipping the cooler, hand grips molded into theexternal shell, stainless steel hardware for strength and durability,axle and wheels with a tow handle for larger sizes, a soft plastic oraluminum tag with adhesive mounting for identification purposes andother convenient features.

[0018] Other preferred embodiments of the present invention includequick wraps usable with beverage packs, individual beverages and forindividual frozen or cold food items.

[0019] These and other features will be evident for the ensuing detaileddescriptions of preferred embodiments along with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0020]FIG. 1 is a perspective view of a preferred embodiment of thecooling system of the present invention.

[0021]FIG. 2 is a side cut-away view of the embodiment of FIG. 1 showingthe lid and a portion of the upper surface of the lower shell.

[0022]FIG. 3 is a side view of the compression strap of the embodimentof FIG. 1.

[0023]FIG. 4 is a front view of the compression strap of FIG. 3.

[0024]FIG. 5 is a side view of the buckle system of embodiment of FIG.1.

[0025]FIG. 6 is a top view a preferred embodiment of the insulativeapron of the embodiment of FIG. 1.

[0026]FIG. 7 is a side view of a preferred embodiment of the dry icepocket of the present invention.

[0027]FIG. 8 is a side view of the dry ice pocket of FIG. 7.

[0028]FIG. 9 is a front view of a preferred embodiment of the lightingsystem of the present invention.

[0029]FIG. 10 is a cut-away view of a preferred embodiment of theshelves-compartmentalization of the present invention.

[0030]FIG. 11 is a rear perspective view of a preferred embodiment ofthe cutting board—compartments of the present invention.

[0031]FIG. 12 is a flat view of a quick-wrap cooler for use withbeverage packs.

[0032]FIG. 13 is a flat view of a quick-wrap for an individual beveragebottle.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0033] A preferred embodiment of the present invention is illustrated inFIGS. 1-11. It is to be expressly understood that the descriptiveembodiments are provided herein for explanatory purposes only and is notmeant to unduly limit the claimed inventions. The preferred embodimentof the present invention includes an insulated cooling system for use intransporting and/or storing items in a chilled environment. Thispreferred embodiment can be in any variety of shapes and sizes as may bedesired by a user. It is also to be expressly understood that theclaimed inventions include not only various combinations of the featuresdiscussed herein but may also include each feature individually inseparately claimed inventions not requiring the other disclosedfeatures.

[0034] In the preferred embodiment, shown in FIG. 1, cooler 10 is in thedesign of a chest. Cooler 10 includes a durable outer surface includingsides 12, 14, 16, 18, bottom 20 and upper lid 22. One example of thematerial for the durable outer surface is three millimeter thick ABSplastic, but other durable materials may be used as well. Handles 24, 26are formed in opposing sides 12, 16. The handles 24, 26 are, in apreferred embodiment, molded into the side surfaces 12, 16 of thecooler. In other embodiments, the handles may be attached.

[0035] Upper lid 22, in this preferred embodiment, is pivotally mountedto the rear surface 18 by living hinges, hinges, retaining strips orother pivoting mechanisms. Alternatively, upper lid 22 can be separatefrom the sides of the chest altogether. The upper lid may also includeside grips to assist in opening the upper lid. Latches 28, 30, discussedin greater detail below, secure the upper lid to the chest. In thepreferred embodiment, the hardware for the cooler 10 are formed of adurable material, such as stainless steel.

[0036] In a preferred embodiment, the cooler 10 includes a soft durabletag, formed of soft aluminum, plastic or other materials. The tag iseither permanently affixed to the cooler, or includes an adhesivesurface to affix onto the cooler. The tag is able to be permanentlymarked by a sharp object with markings, such as a name, to permanentlyidentify the owner of the cooler.

[0037] In the preferred embodiment of the present invention illustratedin FIG. 1, straps 32, 34 compress the upper lid against the side wallsto prevent cold air from leaking out of the cooler. Cam buckles 36, 38assist in the compression of the upper lid against the side walls. Adrain port 40 is formed in the lower section of side wall 12 toperiodically drain melted water from the cooler. The drain port 40 maybe closed with a screw cap, plug or other type of enclosure.

[0038] Reflective surfaces 42 are secured to the side walls 12, 14, 16,18 and upper lid 22. The reflective surfaces 42, in the preferredembodiment illustrated in FIG. 1, are formed from a highly lightdiffractive film, such as PRISMcal® or GENaration™ films, manufacturedby FLEXcon, Spencer, Mass. These films were originally designed fordecals. In the preferred embodiment, illustrated in FIG. 1, these highlylight-diffractive films are effective at reflecting direct sunlight inorder to reduce the amount of heat absorbed by the cooler. These filmsinclude surface diffraction gratings that split white light into arainbow of colors and add a colorful shine to the cooler. These filmsare affixed to the surfaces of the cooler by adhesives. It is to beexpressly understood that other reflective surfaces may be used as wellin order to reduce the heat absorption by the cooler. Preferably, thereflective surfaces have a eighty-five percent UV (ultraviolet)reflective capacity or greater.

[0039] The cooler 10 also includes inner side walls 44 spaced from theouter side walls 12, 14, 16, 18. In the preferred embodiment, the innerside walls are spaced approximately three inches from the outer sidewalls. The cavity formed from this spacing is filled with high densityurethane. This increased thickness and use of high density urethanegreatly improves the cooling retention and/or thermal benefit of thecooler. The upper lid 22 is also filled with high density urethane,preferably in a three inch cavity between the inner and outer surfaces.In the preferred embodiment, the cavity is filled with a highlyexpansive, R7 per inch or greater spray polyurethane insulation. It isto be understood that other insulation materials may be used as well.

[0040] The inner bottom surface of the cooler 10, in the preferredembodiment, is canted slightly downwardly toward the drain port 40. Thedrain port 40 may include a plug to prevent leakage when not desired.The canted bottom surface enables drainage of melted ice without thenecessity of tipping the cooler and upsetting the contents.

[0041] In the preferred embodiment of the present invention, the cooler10 includes a unique sealing mechanism to minimize the leakage of coldair from the cooler. As shown in a cross-section view of the cooler 10in FIG. 2, the upper surfaces 50 of the side walls 12, 14, 16, 18 of thecooler 10 include an engaging seal member 52. In this preferredembodiment, the engaging seal member 52 includes a first angular surface56 extending upwardly at an angle from the outer lip 54. An upper ridgesurface 58 extends parallel to the lip portion 54 and connected betweenfirst surface 56 and second angular surface 60 extending downwardly atan angle to form a “tooth” member. The second angular surface 60 ends ina substantially “v” shaped groove 62. An inner lip portion 64 extendsfrom the groove 62.

[0042] The upper lid 22 includes an opposing sealing member 70 thatincludes corresponding lip portion 72, inwardly extending angular firstsurface 74, a recess surface 76, a downwardly extending angular surface78, and a substantially “v” shaped tooth 80. These features engage in amating relationship with seal member 50 of the upper surfaces 50 of theside walls of the cooler. This engagement minimizes the escape of coldair from inside the cooler 10 to the outside. This greatly improves thethermal benefit of the cooler 10.

[0043] In the preferred embodiment, the seal member 52 of the side wallsand the opposing seal member 70 engage in at least four points ofcontact around the entire circumference of the cooler. It is to beexpressly understood that the seal members 52, 70 can be designed inother embodiments with more or less points of contact. This feature isdesigned to increase the sealing capability beyond the use of flat orminimally engaging surfaces. Other embodiments are also included in thepresent invention. For example, a rubber seal, gasket or other types ofseals could be used as well between the upper lid and the side walls ofthe cooler.

[0044] In a preferred embodiment of the present invention, the cooler 10includes compression straps 32, 34. The compression straps may beaffixed directly onto the cooler 10, inserted in grooves formed onand/or in the outer surfaces of the cooler, or simply secured around thecooler. The compressions straps, in a preferred embodiment are formed ofnylon but may include other materials as well. As shown in FIGS. 3 and4, the compression straps 32, 34 include cam buckles 36, 38. It is to beunderstood that other types of fasteners for the straps may be used aswell. These cam buckles 36, 38 provide a mechanical advantage to enablethe straps 32, 34 to be secured tightly to further force the upper lid22 against the side walls of the cooler 10. These straps are usableparticularly with the seal members 52, 72 as discussed above, but may beused with non-sealing coolers. The straps 32, 34 and buckles 36, 38 alsosecurely lock the upper lid to prevent accidentally opening and/orspillage of the contents of the cooler.

[0045] In the preferred embodiment shown in FIG. 1, the cooler 10 alsomay include buckles 28, 30. These buckles, as shown in greater detail inFIG. 5, are secured to the front panel 14 and upper lid 22 of the cooler10. The clasp 80 of the buckles 28, 30 engage over catch members 82. Therotation of member 84 downward locks the upper lid into compressedengagement with the upper surfaces of the side walls. Preferably, thebuckles 28, 30 are recessed into the front panel and upper lid 22 of thecooler. It is to be expressly understood that these buckles can be usedwith or without the compression straps and with or without the use ofseal members 52, 70. Other types of fasteners may be used as well, suchas snaps, straps, clamps, etc.

[0046] In another preferred embodiment of the present invention, cooler10 also includes an insulated apron 90. Apron 90 is formed from one-halfinch thick EVA foam in this embodiment, although other insulativematerials and sizes may be used as well. Preferably, although notessential, a reflective surface may be applied onto one surface of theapron. Also, the apron 90 should, in the preferred embodiment bewaterproof to protect against ice, melted ice and other liquids. Theapron 90 is of slightly larger dimensions than the inner dimensions ofthe cooler 10. Preferably, the upper edges 92 of the apron are beveled,as shown in FIG. 2. The beveled edges 92 engage against the angled tooth82 of the seal member 70 of the upper lid. Apron 90 also includes hookand loop securing fabric 94 on its upper surface for engagement with theupper lid 22. In the preferred embodiment, the apron 90 also includespockets 96 for insertion of a thermometer, ice, dry ice, utensils, andother items. Handles may also be formed on the apron 90 as well. Inother embodiments of the apron 90, the apron may be formed of vinyl,polyester, plastic or other materials. The apron may also includedoubled or weighted edges to enable the apron to be tucked around thecontents more efficiently. Also, as shown in FIG. 6, the apron mayinclude rounded edges having a slit 98 to allow overlap of the corneredges to enhance tucking the apron around the cooler contents. The aproncan be pushed down against the cooler contents and fit tightly againstthe internal sidewalls of the cooler to capture the cold air against thecontents. When not in use, the apron 90 may be attached to the undersideof the upper lid 22 by the hook and loop fasteners to increaseinsulation.

[0047] The cooler may also include a plastic encased thermometer toensure the proper temperature of the cooler. This thermometer may beleft loose in the cooler, tucked into a pocket in the apron or stored ina compartment formed inside the cooler.

[0048] In an alternative embodiment, the cooler 10 includes dry icepockets 120, shown in FIG. 7. These dry ice pockets may be formed in theinner surface of the cooler 10, formed in the apron 90 or created as aseparate item. The dry ice pockets 120 include an outer elastic band 122that pulls outer flap of the pocket over the inner pocket. As the dryice inside the pocket 120 evaporates, the elastic band 122 pulls theouter flap to form a smaller pocket. The pocket 120 may include sidepleats 124 as shown in FIG. 8 that further enhances the compression ofthe pocket 120. This compression minimizes the evaporation of the dryice thus improving the cooling life of the dry ice. The pocket may alsoinclude a reflective surface as well to reduce the evaporation of thedry ice.

[0049] The cooler 10 also includes, in a preferred embodiment, pourbottles with a layer of insulating foam around for the bottle. Thisallows the bottles and their contents to be pre-frozen as an internalcoolant for the cooler as well as for drinking water.

[0050] In another preferred embodiment, the cooler 10 of the presentinvention includes one or more battery powered, switch operated lights,such as lights 100, 102, 104, 106 shown in FIG. 9. These lights enableaccess into the cooler 10 even in dark environments. In an alternativeembodiment, the cooler 10 includes clips or hook and loop fasteners intowhich small flashlights be held.

[0051] Cooler 10, in another preferred embodiment, includes groovesformed horizontally and/or vertically in the inner surfaces of thecooler 10. Shelves can be inserted into the horizontal grooves whileseparators can inserted in the vertical grooves. This providescompartment separation for the cooler to isolate the contents. Thecooler may also include tubs, trays, racks or other structures that canbe held in the grooves.

[0052] Cooler 10 may also include an axle and wheels permanently affixedto the bottom surface of the cooler or grooves that enable an axle andwheels to be snapped onto as needed. The cooler 10 may also include apull-out handle or strap to tow the cooler.

[0053] In another preferred embodiment, the cooler 10 includes abuilt-in cutting board insert 120 as shown in FIG. 10 on the upper lid22. The upper lid 22 may also include a built in compartment 126 havingan upper lid 128. The compartment 126 is useful for storing utensils,paper goods and other items that do not need to be a chilledenvironment. The compartment can be accessed externally without openingthe internal contents of the cooler.

[0054] Another alternative preferred embodiment is illustrated in FIG.12. This cooler is intended for use as an individual cold purchaseddrink wrap. The drink wrap cooler 200 is formed of a flexible foaminsulation material, such as expanded foam, neoprene, etc. This drinkwrap cooler includes a reflective surface, such as discussed above, onthe external side of the cooler. Edge surfaces 202 include a strip ofadhesive tape with a removable protective paper edge. Fold lines 210 maybe perforated. The size and shape of the cooler is variable toaccommodate typical six-pack sizes of beverage cans or bottles,twelve-pack sizes, single serving sizes of cans or bottles, etc. Therectangular, six-pack size is illustrated in FIG. 12, but the claimedinvention is not intended to be limited to this particular size andshape.

[0055] In use, the beverage pack is placed in the middle of the coolerwrap 200. Short edge is folded up around the top of the pack within onelong edge folded to meet over the top. The adhesive strip 202 is used toconnect the two edges and seal the corners at the same time. This isrepeated for each side and edge until all four edges are taped together.The handle 212 will meet tightly across the middle top of the pack andis inserted through handle holes 214, 216. In smaller sizes, the cooler200 will use adhesive strips above and below the opening of the handle204 to attach to each other. In the larger sizes, one flap will foldover the existing pack handle using an adhesive strip to secure it inplace and another adhesive strip along the edge to secure the remainingcorner.

[0056] Other embodiments of the wrap cooler include eliminating thehandles. The edges completely fold over the top with an adhesive stripon one flat situated on the top to enclose the cooler around thebeverage. The wrap cooler can also include fitted and precut holes forbeverage box handles. Another embodiment uses pre-made cooler wraps withpre-adhered, stitched or hook and loop fasteners on the edges as aslip-on cover. Another embodiment uses hook and loop fasteners in lieuof the adhesive strips. Advertising may also be applied to the externalsurfaces and flaps of the wrap coolers.

[0057] Another embodiment of the wrap cooler is illustrated in FIG. 13.The wrap cooler 300 is intended for use with single cylindricalcontainers, such as a wine bottle. The wrap cooler 300, formed ofmaterials as discussed above, includes slits 320, 322, 324 cut into thebottom of the wrap cooler at intervals 302, 304, 306, 308. One section308 includes an adhesive tab 310 (or hook and loop fasteners) as well astabs 312, 314 along the length of the cooler and tabs 316, 318 at theends of the pull around wraps at the top of the wrap cooler. The bottleis placed in the middle so the bottom of the bottle is at the top of theslits. Each slit is folded over the bottom of the bottle. The two middletabs 312, 314 are secured around the bottle. The top arms 326, 328 arewrapped around the bottle and secured. An alternative embodiment simplyengages about substantially the entire outer surface of a bottle or boxwith an elastic fit to account for handles, or other features on thebottle or box.

[0058] Individual wrap coolers, in another preferred embodiment, arealso designed for use with frozen or cold food, such as ice cream,Popsicles, etc. Pockets may be created to wrap such items.

[0059] It is to be expressly understood that the descriptive embodimentsare provided for explanatory purposes and are not meant to limit theclaimed inventions. Also, the claimed inventions may include one or moreof the descriptive features and their equivalent structures eithersingly or in various combinations of one another.

What is claimed is:
 1. An insulated cooler, said cooler comprising: anouter wall surface on the sides and the bottom of said cooler; an innerwall surface on the sides and bottom of said cooler; an insulatingmaterial between said outer wall surface and said inner wall surface;and an upper lid; and sealing mechanism for minimizing the escape ofcold air from said cooler.
 2. The cooler of claim 1 wherein said coolerincludes: a highly reflective surface applied to the outer surface ofsaid upper lid and said outer wall surface on said sides of said cooler.3. The cooler of claim 2 wherein said highly reflective surfaceincludes: a reflective surface of eighty-five percent UV rating orgreater.
 4. The cooler of claim 2 wherein said highly reflective surfaceincludes: an adhesive surface for affixing onto said surfaces of saidcooler.
 5. The cooler of claim 1 wherein said sealing mechanismincludes: a sealing member extending downward from the lower surface ofsaid upper lid; and an opposing sealing member extending upward from theupper surface of said side surfaces of said cooler for mating engagementsaid sealing member on said upper lid to minimize the escape of cold airfrom said cooler when said upper lid is closed.
 6. The cooler of claim 5wherein said sealing member of said upper lid includes: a plurality ofcontact surfaces, and said opposing sealing member includes a pluralityof contact surfaces for engaging with said plurality of contact surfacesof said sealing member of said upper lid.
 7. The cooler of claim 1wherein said cooler includes: a mechanism for compressing said upper lidagainst the upper surfaces of said sides of said cooler.
 8. The coolerof claim 7 wherein said mechanism for compressing said upper lid againstthe upper surfaces of said sides of said cooler includes: at least onecompression strap; and a mechanism for tightening said compressionstrap.
 9. The cooler of claim 7 wherein said mechanism for compressingsaid upper lid against the upper surfaces of said sides of said coolerincludes: at least one fastener mechanism for tightening said upper lidagainst said upper surfaces of said sides of said cooler.
 10. The coolerof claim 1 wherein said cooler further includes: an insulating apron forcovering items contained in said cooler.
 11. The cooler of claim 1wherein said cooler further includes: at least one light mounted withinsaid cooler.
 12. The cooler of claim 1 wherein said cooler furtherincludes: a drain port; and a bottom surface of said cooler cantedtowards said drain port.
 13. The cooler of claim 1 wherein said coolerfurther includes: about three inches of a lightweight material having aninsulation rating of at least R7 per inch.
 14. The cooler of claim 1wherein said cooler further includes: a thermometer for monitoring theinternal temperature of said cooler.
 15. The cooler of claim 1 whereinsaid cooler further includes: a pocket formed of insulated material forholding dry ice; and an elastic mechanism for compressing said pocket assaid dry ice evaporates.
 16. The cooler of claim 1 wherein said coolerfurther includes: at least one built in compartment that is externallyaccessible.
 17. The cooler of claim 1 wherein said cooler furtherincludes: compartments for holding containers.
 18. The cooler of claim 1wherein said cooler further includes: shelve compartments.